Turf pallet and system

ABSTRACT

A lightweight turf pallet is formed of High Density Polyethylene and is formed by a twin-skin vacuum moulding process under high pressure. The pallet has top and bottom faces each with an array of frusto-conical cavities formed in rows on each face, the cavities on opposed faces being coaxial and joined at their apices to form a web therebetween. A system for constructing a recreation or sporting surface comprising such pallets, together with corner joiner members and surface pads is also described and claimed.

FIELD OF THE INVENTION

The present invention relates to a turf pallet and to a system for constructing a recreation or sporting surface. More particularly the invention relates to a lightweight turf pallet for supporting natural or synthetic turf, in use, in storage, or during the growth period for natural turf in a manner whereby transportation, installation and replacement are readily accommodated and other factors such as drainage and aeration are optimized.

BACKGROUND OF THE INVENTION

Prior art turf pallets consist of large trays formed from steel composite and rely on their mass to stay in position. They suffer the disadvantage of being heavy and cumbersome and, therefore, are difficult to transport and place in position. They may also suffer rust and corrosion which can ultimately cause failure of the pallet in use.

It is conceivable that lighter material than steel could be used to construct the pallet but the problem then is to provide the strength and rigidity necessary to support loads estimated to be around 1500 kg/ft².

Accordingly it is an object of the present invention to provide an improved turf pallet that overcomes one or more of the disadvantages associated with existing turf pallets, or that at least provides a useful alternative.

A further object is to provide an improved system for constructing a recreation or sporting surface.

SUMMARY OF THE INVENTION

In one form of the invention provides a lightweight turf pallet formed of plastics material having spaced top and bottom faces and comprising an array of generally frusto-conical cavities formed in each face, the cavities on opposed faces being coaxial and being joined at their apices to form a web therebetween.

Another form of the invention provides a system for constructing a recreation or sporting surface, said system including a series of pallets as described the preceding paragraph, corner joiner members for joining the adjacent corners of four said pallets together, surface pads comprising a plastics sheet for placing on top of each said pallet to provide sound deadening in use, said surface pads having holes therein for drainage purposes, and natural or synthetic turf on top of said surface pads and retained thereon by said perimeter member.

BRIEF DESCRIPTION OF THE DRAWINGS

In order that the invention may be more readily understood one particular embodiment will now be described in more detail with reference to the accompanying drawings wherein:

FIG. 1. is an exploded view of the components of a turf pallet system according to the invention;

FIG. 2 is a part perspective end view of a turf pallet as shown in FIG. 1;

FIG. 3 is a part perspective sectional view of the pallet shown in FIG. 2;

FIG. 4 is a perspective underside view of the pallet shown in FIGS. 1-3;

FIG. 5 is a perspective view of a joiner member for joining the corners of four adjacent pallets, shown in position connected to the pallet of FIGS. 1-4; and

FIG. 6 is similar to FIG. 2 but shows the interconnection of two like parts which together form a pallet according to this particular embodiment of the invention.

A turf pallet as provided according to the present embodiment consists essentially of two separate parts (10) which are joined together in the manufacturing process to provide a flat square tray for supporting natural or synthetic turf (11). The separate parts (10) are moulded from HDPE using a vacuum moulding process under high pressure. The separate parts (10) each include spaced parallel reinforcing members (12) formed from steel and fully enclosed within the moulding.

As is evident in FIGS. 1 and 2, the reinforcing members (12) consist essentially of channel members having flanges (13) on the extremities of the opposed sides of the channel. The reinforcing members (12) define inverted channels extending across each of the parts (10) on the underside thereof. The opposed sides of the separate parts (10) have grooves (14) extending part way along the opposed sides from each end and adjacent the top and bottom edges respectively. Separate joiner members (15) formed from aluminium extrusion and having essentially an I-beam construction are forced along the opposed edges to engage the grooves (14) and attach the two parts (10) together.

When the two parts (10) are rigidly joined together to form a flat square tray or pallet, galvanised steel plates (16) are riveted or screwed through the HDPE to the flanges (13) of the reinforcing members (12), as is shown more clearly in FIGS. 2 and 4. The plates (16) extend across both the separate parts (10) and, in combination with the reinforcing members (12) form open-ended pockets suitable for receiving the tynes of a forklift truck.

Turning now to FIGS. 2, 3 and 6, the internal construction of the parts (10) forming the pallet or tray is shown in more detail. As mentioned previously the parts are moulded by means of a high pressure vacuum moulding process in a twin skin configuration and internally have an array of essentially frusto-conical pockets forming cavities in the upper and underside of the parts. The pockets on opposed sides are joined at their apices (17) and a hole (18) is provided between opposed cavities.

A rebate (19) extends around three sides of each of the parts (10) such that when the two parts are joined together the rebate extends around the perimeter of the resulting pallet or tray. The rebate accommodates a moulded perimeter member (20) which, when in place, provides an upstanding wall that extends around the perimeter of the pallet to retain turf (11) and other material such as sand/rubber mix (not shown) on the surface of the pallet. A plastics sheet (22) of ABS material is placed on top of the pallet and in use, is located under the turf (11). The sheet (22) is provided with holes therein to allow drainage between the turf and the pallet.

As can be seen in FIG. 5, a corner joiner (23) is provided for joining the adjacent corners of four pallets together in use. The joiner member (23) has four spaced upstanding protrusions (24) of essentially conical shape that are adapted to locate in corresponding apertures (25) (FIG. 4) in the underside of each pallet. A central cruciform (26) on the corner joiner (23) locates and supports the respective corners of the pallets.

As mentioned previously the turf (11) may be natural or synthetic turf. In the case of natural turf, the turf is grown on the tray which then acts as a lightweight transportable pallet and finally as a support device for the turf in use. In other words the plastics pallet of the present invention provides a turf growing tray, a transportable pallet and a base surface for a sporting or recreation surface. Whilst the pallet according to the particular embodiment described above is formed essentially from two components that are joined together, a second embodiment (not shown) provides a single part pallet thus avoiding the need for joining two parts together.

The unique internal design comprising opposed frusto-conical cavities enables the pallet to carry the high compression loadings required for the particular use and also allows even air circulation and drainage under the surface of the turf for providing a stable temperature. The plastics sheet (22) provides sound deadening and minimises thump and echo from activity on the surface, whilst also facilitating drainage.

Clearly, the invention is not limited to the particular embodiment as described above as modifications may be readily incorporated. For example the internal design of the pallet may be modified provided sufficient strength is attained for long term use. Also, whilst the described embodiment relates to a square pallet it could equally be a rectangular shape other than square. Conceivably it could be non-rectangular provided the shape was such to allow interconnection of the pallets to form a continuous surface. 

1. A lightweight turf pallet formed of plastics material having spaced top and bottom faces and comprising an array of cavities formed in each face, the cavities on opposed faces being coaxial and being joined at their bases to form a web therebetween.
 2. A pallet according to claim 1, wherein said cavities are substantially frusto-conical and said oppose cavities are joined at their apices.
 3. A pallet according to claim 2, wherein said pallet is formed by a twin-skin vacuum moulding process under high pressure, and steel reinforcing is provided therein, said reinforcing defining at least part of tyne pockets facilitating lifting and transportation of the pallet using a fork lift.
 4. A pallet according to claim 3, wherein said web has one or more drainage holes therein.
 5. A pallet according to claim 4, made primarily from High Density Polyethylene (HDPE).
 6. A pallet according to claim 1, manufactured from two like parts arranged coplanar and joined along adjacent edges to form a rectangular pallet.
 7. A pallet according to claim 6, wherein said parts are joined by aluminium joiner members that are slid between the two parts from opposite edges and interlock with grooves provided in said adjacent edges.
 8. A pallet according to claim 5, wherein said reinforcing comprises spaced U-shaped channels extending across the width of the pallet and enclosed within said HDPE, said channels having outwardly directed flanges on the sides of the channels and being open in a direction towards the underside of the pallet, and a steel plate extending across the width of the pallet and fixed, through said HDPE, to said flanges, to form said tyne pockets.
 9. A pallet according to claim 8, wherein a rebate extends around the upper perimeter of the pallet to receive a moulded rectangular perimeter member providing an upstanding wall for retaining said turf on said pallet.
 10. A system for constructing a recreation or sporting surface, said system including a series of pallets as defined in claim 1, corner joiner members for joining the adjacent corners of four said pallets together, surface pads comprising a plastics sheet for placing on top of each said pallet to provide sound deadening in use, said surface pads having holes therein for drainage purposes, and natural or synthetic turf on top of said surface pads and retained thereon by said perimeter member.
 11. A system according to claim 10, wherein said surface pads are formed of acrylonitrite butadiene styrene (ABS).
 12. A system according to claim 10, wherein said corner joiner members are plastics pads with generally conical upstands for engaging in corresponding said cavities in the underside of each pallet at said corners.
 13. A system according to claim 11, wherein said corner joiner members have an upstanding central cruciform for locating and supporting the respective corners of the pallet. 